Dimensionally stable laminate with removable web carrier and method of manufacture

ABSTRACT

A balanced dimensionally stable laminate uses a web carrier which is removably attached to a layer of the laminate during lamination and processing. The web carrier maintains dimensional stability of the layers of the laminate during lamination and processing and after removal of the web carrier. The web carrier is removed if at all only after the laminate is formed and processed. The bonding force of the web carrier with at least one of the polymers layer resists forces which would otherwise dimensionally distort the layers of the laminate or design features thereof during lamination, particularly in thermal roll-forming lamination. The layers of the laminate, which may include print and texture design features, remain dimensionally stable after removal of the web carrier. The web carrier can be removed at any time prior to or after final application of the laminate to a substrate.

RELATED APPLICATIONS

[0001] This application claims priority to a provisional U.S.application, Ser. No. 60/413,429, filed Sep. 24, 2002, entitled,DECORATIVE LAMINATE WITH IMPROVED PROCESSING AND TEXTURE RETENTIONPROPERTIES.

FIELD OF THE INVENTION

[0002] The present invention pertains generally to laminate structuresmade with polymeric films and, more particularly, to polymeric filmlaminates with decorative features including textures and printpatterns.

BACKGROUND OF THE INVENTION

[0003] Decorative and structural panels for architectural and transportvehicle applications commonly have a decorative laminate outer coveraffixed to a substrate. Decorative laminates are typically constructedwith an exterior surface that is either an embossed texture, printpattern or both aesthetic design features. The decorative laminate isthen formed and adhered to an underlying structural substrate layer.Maintaining uniformity of the texture and print pattern design featuresof the decorative laminate throughout the manufacturing process is veryimportant.

[0004] Generally, such laminates are constructed using multiple layersof various films laminated together under high temperature and pressure,and/or embossed (again at high temperature and pressure) at differentstages in a continuous roll-forming manufacturing process. U.S. Pat. No.5,976,671 discloses two conventional constructions of a decorativelaminate. In the first construction, the decorative laminate possessestwo layers: a first embossed layer that imparts surface release to thelaminate and a second decorative layer that overlies the first. Thisdecorative layer is typically either screen printed (i.e.,multi-graphics) or integrally colored (i.e., internally pigmented).Generally, the single laminate includes a textured layer consisting of athermo-setting or thermoplastic emboss resin overlayed with a decorativelayer composed of a thin layer of pigmented thermo-plastic film.

[0005] Other prior art teaches a second type of construction for adecorative laminate with an embossed layer, a decorative layer, and atleast one structural layer. Conventional methods for the manufacture ofsuch laminates are limited by the properties of the materials used whichimpose limitations on the extent to which the combined layers can beheated, stretched and further processed in casting and roll-formingmachinery without adversely affecting the dimensional stability of thefinal product.

[0006] Present materials and manufacturing techniques do not enable themanufacture of a non-reinforced laminate in a continuous laminationprocess which results in a laminate having low distortion or dimensionalstability. Laminates have three basic dimensions which can berepresented by reference to x, y, and z axes, where the z-axisrepresents the thickness of the laminate. In conventional laminates,permanent distortion occurs along the x or y axis, or both, when thelaminate is heated and stretched in one or more directions as a resultof forces applied in a mechanical lamination process such asroll-forming. As the laminate cools it retains such distortion. Further,decorative laminates manufactured with materials and manufacturingtechniques currently known result in a laminate, which when applied to asubstrate under heat and vacuum, transmits defects in the substrate andloses texture retention. Therefore, a need exists for a laminateproducible from materials with the desired aesthetic properties oftexture and graphical features, and which does not distort or deformdimensionally in a roll-forming manufacturing process.

[0007] Some polymer films which are used as layers in laminates areprovided with a pre-applied layer bonded directly to the polymer film byone of several conventionally known methods such as solution casting. Inlaminating and roll-forming techniques used in the art, films with no orlow-orientation have relatively high elongation and shrinkage attemperatures required for embossing, which makes creating a laminateproduct in a continuous roll difficult. It is standard practice in theart to remove carrier layers prior to lamination of the polymer film toany other layer in a roll forming process, primarily so that the carrierdoes not interfere with the processing, e.g., bonding and texturing, ofthe polymer film. Removal of the carrier however, allows the film todeform or distort in multiple dimensions, particularly when the laminateis mechanically processed. Distortion is magnified by additional layersin the laminate.

SUMMARY OF THE INVENTION

[0008] The present invention provides a novel laminate structure andmethod of manufacture which utilizes a removable web carrier whichremains on one or more of the polymer films of a laminate of two or morepolymer films as the films are laminated together, for example in acontinuous roll-forming process. The invention uses a web carrier whichis selected to balance with the physical properties of the other layersof the laminate product, wherein the web carrier is removably attachedor bonded to at least one of the layers of the laminate, and therebyprovides the laminate resistance to distortion which can otherwise occurduring lamination as a result of heat and mechanical strain. Conversely,the invention includes the selection of laminate layers to balance withphysical properties of a removable web carrier to minimize distortion ofthe laminate layers when laminated and/or processed with the web carrierattached. Laminates of the invention have improved texture retentionproperties and dimensionally stable print patterns as the result offorce balancing with a removable web carrier.

[0009] The invention involves the selection of layers of a laminate,including at least one layer which is attached to or mated with a webcarrier, such that when the layers are laminated together and/orembossed, the bonding force of the web carrier is sufficient to resistdistortion of any of the layers of the end laminate product during andafter lamination and other processing.

[0010] In accordance with one general aspect of the invention, there isprovided a laminate structure which has a first polymer film, a webcarrier attached to a first side of the first polymer film, a secondpolymer film positioned parallel to and adjacent to a second side of thefirst polymer film, wherein a bonding force of the web carrier with thefirst polymer film overcomes forces which tend to distort the first andsecond polymer films during lamination, and the laminate of the firstand second polymer films maintains dimensional stability after removalof the web carrier.

[0011] In accordance another general aspect of the invention, a laminateincludes a first polymer film, a second polymer film positioned in aplane parallel to and on one side of the first polymer film, a webcarrier positioned in a plane parallel to the first and second polymerfilms and removably attached to another side of the first polymer film,the first and second polymer films being laminated together, wherein thelaminated first and second polymer films are free from distortion afterlamination as a result of the removable attachment of the web carrier tothe first polymer film, the web carrier being removable from the firstpolymer film without distortion of the end laminate.

[0012] The invention further provides a low distortion laminate producedby a process comprising the steps of providing a first polymer film,positioning a second polymer film in a plane parallel to and on a firstside of the first polymer film, removably attaching a web carrier to oneof the first or second polymer films, laminating the first and secondpolymers films, and removing the web carrier without distortion of thelaminated first and second polymer films. Print and embossing resinlayers may be added to the laminate, for example between the polymerfilm layers, without inducing distortion during or after the laminationprocess.

[0013] In accordance with another general aspect of the presentinvention, there is provided a dimensionally stable laminate producthaving a first polymer film, a second polymer film positioned in a planeparallel to and on one side of the first polymer film, and a web carrierpositioned in a plane parallel to the first and second polymer films andremovably attached to another side of the first polymer film, the firstand second polymer films laminated together, the laminated first andsecond polymer films being free from distortion relative to dimensionsof the first and second polymer films prior to lamination as a result ofthe removable attachment of the web carrier to the one side of the firstpolymer film, the web carrier being removable from the laminated firstand second polymer films which remain free from distortion ofdimensions, print or texture features after removal of the web carrierfrom the laminate. A texture can be applied to the laminate through theweb carrier prior to removal of the web carrier. A second web carriercan be used in contact with the second polymer film.

[0014] These and other aspects of the invention are herein described indetail, with reference to the accompanying drawings and Examples, whichare representative of some of the preferred and alternative ways inwhich the concepts of the invention may be practiced.

BRIEF DESCRIPTIONS OF THE FIGURES

[0015]FIG. 1 is a schematic illustration of a laminate structure inaccordance with the present invention;

[0016]FIG. 2 is a schematic illustration of a roll-forming laminationprocess which can be used to construct a laminate in accordance with thepresent invention;

[0017]FIG. 3 is a schematic illustration of an alternate embodiment of alaminate structure in accordance with the present invention;

[0018]FIGS. 4A and 4B are schematic illustrations of a geometric patternon a layer of a laminate structure, and

[0019]FIG. 5 is a schematic illustration of an embossing process whichcan be used in accordance with the present invention.

DETAILED DESCRIPTIONS OF PREFERRED AND ALTERNATE EMBODIMENTS

[0020]FIG. 1 schematically illustrates a laminated structure, indicatedgenerally at 10, which includes a first layer 100 which is preferably apolymer film, which may be any material suitable for construction of alaminate, and preferably a polymeric film (also referred to herein as apolymer film) such as for example polyvinyl fluoride (PVF),polyvinylidene fluoride, acrylic, polycarbonate, polyvinyl chloride,PETG, urethane, ABS or polyester. A preferred commercially availablepolymer film for the first layer 100 is a polyvinyl fluoride film soldas Tedlar® PVF film, manufactured by E.I. du Pont de Nemours ofWilmington, Del., and more preferably Tedlar SP PVF which is cast on toa polyester web carrier, and which provides excellent conformability,color stability, chemical resistance, thermo-formability and durability.

[0021] A second layer 200, which is also preferably a polymer film ofthe same or different material than first layer 100, lies in a planeadjacent and parallel to first layer 100. Additional layers may becombined with first and second layers 100, 200, in any compatible numberor combination, and with varying thickness, densities, materialproperties or other variables. For decorative structural products suchas panels, a print or print layer 20 is provided proximate to firstpolymer film 100 as shown, or alternatively proximate to second polymerfilm 200. The bond of the web carrier to one of the first or secondpolymer films, or to both, maintains dimensional stability of thepolymer films and any print pattern applied thereto, thereby avoidingany distortion of the print as might otherwise result from stresses atthe interface of the laminate layers.

[0022] Intermediate layers 70 are provided between layers 100, 200preferably in the form of an embossing resin or other suitable material,which provides additional thickness to the laminate 10, and whichaccepts an embossed texture applied through layer 100, as furtherdescribed herein.

[0023] At an outer surface layer of the laminate 10, a web carrier layer50 (referred to herein generally as a “web carrier”) is provided, whichis bonded, cast or otherwise attached to one side of either the firstlayer 100 or the second layer 200 or both, opposite the interfacingsides of the first and second layers 100, 200. As noted, the web carrier50 as an outer layer of the laminate 10 can be located on the firstlayer 100 only, the second layer 200 only, or on both the first andsecond layers 100, 200. As used herein, the terms “first”, “second”,“top”, “bottom” are used for descriptive reference only and are not tobe construed as limiting the laminate 10 or any of its layers to anyparticular orientation or arrangement.

[0024] The material of the first and second polymer film layers may bepolyvinyl fluoride (PVF), polyvinylidene fluoride, polyvinyl chloride,acrylic, polyester, polycarbonate, PETG, urethane, ABS or other suitablefluorinated materials or alloys thereof. A presently most preferredmaterial for a polymer film with a removably attached web carrier toserve as the first or second layer 100, 200 with a web carrier 50 isType 8 Tedlar® SP PVF film which is cast on to a polymer sheet whichserves as a web carrier in the present invention. In accordance with theinvention, the web carrier 50 is left on the accompanying layer 100, 200during and throughout lamination and other processing of the laminate10, including embossing and/or printing, and removed if at all from thefinished laminate 10 upon completion of lamination and processing, orafter final installation of the laminate to thereby serve as aprotective mask, as further described herein.

[0025] The web carrier 50 can be any suitable material which can beremovable bonded to one or both of the first, second layers 100, 200,and wherein the removable bond between the web carrier and at least oneof the first or second layers 100, 200 is sufficient to maintaindimensional stability of the laminate structure formed by lamination ofthe first and second layers 100, 200 and any intermediate layers 70. Inthe case of Tedlar SP polyvinyl fluoride film, a removable bond betweenthe web carrier 50 and the first layer 100 is formed by casting the PVFfilm onto the web carrier and dried without orientation. However, otherforms of attachment of a web carrier to one or both of the polymerfilms, such as for example by releasable adhesive, may be suitableprovided the web carrier 50 can be removed after lamination or otherprocessing of the polymer film in accordance with the invention.Examples of materials which may be suitable for use as the web carrier50 include, without limitation, polyester, paper, rigid polymer films,polycarbonate or polyimide, or any other dimensionally stable materialwhich can be removably bonded to one or both of the polymer film layers.As used herein, the term “dimensionally stable” refers to the propertyof a web carrier which does not distort or deform when adhered to one ormore of the polymer films, and maintains its dimensions and thedimensions of the layers of a laminate to which it is attached withindesign parameters for the end use application of the laminate.

[0026] Intermediate layers 70 serve as an embossing layer or layers,applied or otherwise laminated to the first or second layers 100, 200 asshown. The embossing layer is any suitable thermoplastic or thermosetresin, cast, calendared or extruded, which functions to bond the firstand second layers 100, 200 internal to laminate 10, and provides a depthdimension to the laminate 10 which accepts and retains an embossedtexture.

[0027] The laminate 10 is designed to be balanced in the sense thatstresses induced in the layers 100, 200, and through intermediate layers70 during lamination and texture/printing processing do not overcome thedimensional stability which the bond of the web carrier to at least oneof layers 100, 200 provides. This results in the finished laminate 10having dimensional stability with respect to any applied texture orprint pattern. The balancing of forces between the layers 100 and 200,and the bond of the web carrier 50 with one or both of these layers, isachieved by selection of materials based primarily on thickness andorientation, such that lamination processing does not produce forceswhich exceed the dimensional stability provided by the bond of the webcarrier 50 to one or both of layers 100, 200. The thickness and bondingforce of the web carrier 50 are also selected or varied to balance theforces acting on layers 100, 200 during lamination processing to achievea dimensionally stable laminate 10.

[0028] The web carrier 50 holds the high distortion film in place duringmanufacture and processing of the laminate 10, as shown in FIG. 2. Thisallows for better texture retention because higher temperatures can beutilized during processing without stretching or distortion of thelaminate. It also allows geometric prints on a continuous basis becausethe print is not distorted during processing. It has been discovered bythe inventors that it is preferable to utilize a layer in the laminateconstruction during the manufacturing process that was removable fromthe laminate without affecting the physical characteristic of thelaminate after lamination and/or embossing. A web carrier, which isattached to one of the polymer films, e.g. by solution casting, meltcasting or roller application of the polymer to the web carrier, willnot adversely affect the texture, pattern or other aesthetic quality ofthe laminate, and will not cause distortion, wrinkling or dimensionalskewing of the laminate. In a preferred embodiment, graphics or otherdecoration are applied to the laminate construction by laminating a filmor printing art to the Tedlar SP opposite the web carrier side.

[0029]FIG. 2 illustrates a roll-forming type lamination process by whicha dimensionally stable laminate 10 of the invention is made, wherein thecombined layers 50, 100, 20, 70, 200, and any additional layers are fedfrom the left side against a first roller A into an embossing rollercombination B and C, with the embossing roller B imparting a texture tothe laminate through the web carrier 50 and first layer 100, into theembossing resin 70, as shown in cross-sectional detail in FIG. 5. Thelaminate 10 then proceeds over rollers D and E, after which the webcarrier 50 is removed on to spooling roller F, with the finishedlaminate 10 being loaded on to roller G. This illustrates how, in acontinuous laminate production process, the web carrier 50 remains anintegral part of the laminate throughout permanent bonding of the layersand texturization, and is then removed prior to loading the finishedlaminate on to a delivery roller. The presence and bonding force of theweb carrier to the laminate throughout the process causes the finishedlaminate to be dimensionally stable. The web carrier 50 can be left onthe laminate 10 as a protective mask until or after final application ofthe laminate 10 to a substrate.

[0030] Tests of texture retention, formability, and print distortion,and other standard tests were performed on a laminates 10 made by themanufacturing processes of the invention. For texture retention at 280°F., the laminate showed a change in the 60 degree gloss of less than 5gloss units (compared prior art laminates without a polymeric film caston to a low distortion carrier is 10 gloss units). Forthermoformability, the laminate 10 had a 3 inch draw in less than 5 inchvacuum at 212° F. (compared to prior art laminates with a 3 inch draw in8 inch vacuum at 212° F.). For print distortion, the product has lessthan 2% uniform distortion, which is substantially less than prior artlaminates which have nonuniform distortion.

[0031]FIG. 3 illustrates removal of the web carrier 50, from one or bothsides of the laminate 10, irrespective of the particular productionprocess used.

[0032]FIG. 4A illustrates an overhead view of a finished laminate 10 ofthe invention made with an attached web carrier as described, and whichhas a visible print pattern of print layer 20 as part of the laminatestructure as described, showing the dimensional stability of the patternwith respect to the x and y axes, with the vertical arrow on the leftindicating the direction of travel of the laminate through roll-formingmachinery. The print pattern P remains dimensionally stable due to thefact that the bonding force of the web carrier with one of the polymerfilms is sufficient to resist forces which would otherwise distort oneor more layers of the laminate during lamination or texture processing.FIG. 4B illustrates a laminate with a print pattern P which isdistorted, i.e., not dimensionally stable, due to elongation generallyalong the y axis in the direction of roll-forming machine travel asindicated by the arrow on the right. The distorted print pattern is aresult of unbalanced forces between layers of the laminate caused byheat-induced shrinkage and mechanical strain which exceeds the strengthof the bonding force between the layers, and the absence of an attachedweb carrier which maintains the layers in dimensionally stablealignment, as in the laminate of FIG. 4A.

[0033] The following examples of dimensionally stable laminates madewith an attached web carrier are provided as further disclosure ofpreferred and alternate embodiments and do not otherwise limit the scopeof the invention.

EXAMPLE 1

[0034] In this example, a 1 mil polyester carrier layer 50 and firstlayer 100 are provided in the combined form of Tedlar SP, Type 8, andlaminated with 4 mils of embossing resin, and a 2 mil layer of Type 5Tedlar.

[0035] a. polyester web carrier, 1 mil

[0036] b. 0.5 mil polyvinylflouride, non-oriented film solution cast onto web carrier, e.g. Type 8, Tedlar SP;

[0037] c. print layer (optional)

[0038] c. 4 mil embossing resin;

[0039] d. 2 mil polyvinylflouride, back ply film, e.g. Type 5 Tedlar;

[0040] e. substrate application adhesive (optional), e.g. heat-activatedor pressure-sensitive.

[0041] This laminate is produced with a pre-coating of embossing resin,e.g. 1-2 mils, followed by lamination to a printed Tedlar SP film layerand to another layer of embossing resin, 1-2 mils, and to a back plylayer of Tedlar Type 5, e.g., 2.0 mils. The laminate is embossed throughthe Tedlar SP layer with the web carrier attached and into the embossingresin. The laminate can be coated with a substrate application adhesive,which is heat activated or pressure sensitive. The web carrier can bestripped from the Tedlar SP layer after lamination, or after finalapplication to a substrate to thereby serve as a protective mask duringshipping, handling and final application.

EXAMPLE 2

[0042] A relatively lighter weight dimensionally stable laminate is madewith Tedlar SP as a face ply, a 2 mil thick layer of embossing resin,and a formable 2 mil thick back ply.

[0043] a. web carrier, e.g. 1 mil polyester;

[0044] b. 0.5 mil polyvinylflouride, non-oriented film solution cast onto web carrier, e.g. Type 8, Tedlar SP;

[0045] c. print layer or layers (optional);

[0046] d. embossing resin, 2 mils;

[0047] e. back ply film, 2 mils, Type 5 Tedlar;

[0048] f. substrate attachment adhesive (optional).

[0049] This laminate is produced with a pre-coating of embossing resin,e.g. 1.0 mils, followed by lamination to a printed Tedlar SP film layerand to another layer of embossing resin, and to a back ply layer ofTedlar Type 5, e.g., 2.0 mils. The laminate structure is embossedthrough the Tedlar SP layer with the web carrier attached and into theembossing resin. The laminate can be coated with a substrate applicationadhesive, which is heat activated or pressure sensitive. The web carriercan be stripped from the Tedlar SP layer after lamination, or afterfinal application to a substrate to thereby serve as a protective maskduring shipping, handling and final application.

EXAMPLE 3

[0050] A dimensionally stable laminate with a screen printed design andwhich may also be textured.

[0051] a. web carrier;

[0052] b. 0.5 mil polyvinylflouride, non-oriented film solution cast onto web carrier, e.g. Type 8, Tedlar SP;

[0053] c. print layer or layers, geometric or linear;

[0054] d. embossing resin (e.g. 2.0 mils);

[0055] e. embossing resin (e.g. 2.0 mils);

[0056] f. back ply film, e.g. Tedlar (2.0 mils);

[0057] g. substrate application adhesive (optional).

[0058] This laminate is produced with a pre-coating of embossing resin,e.g. 1-2 mils, followed by screen printing a geometric or linear printeither on the embossing resin or on the back of the SP Tedlar layer,laminating the embossing resin layers, and laminating to a back plylayer of Tedlar Type 5, e.g., 2.0 mils. The laminate structure isembossed through the Tedlar SP layer with the web carrier and into theembossing resin. The laminate can be coated with a substrate applicationadhesive, heat activated or pressure sensitive. The web carrier can bestripped from the Tedlar SP layer after lamination, or after finalapplication to a substrate to thereby serve as a protective mask duringshipping, handling and final application.

EXAMPLE 4

[0059] A printed dimensionally stable laminate with a print designapplied by a rotary or gravure printing process, and which may also betextured by embossing, with a web carrier on a face ply or top layer ofthe laminate, which may be removed when the laminate structure iscompleted.

[0060] a. web carrier;

[0061] b. 0.5 mil polyvinylflouride, non-oriented film solution cast onto web carrier, e.g. Type 8, Tedlar SP;

[0062] c. print layer or layers, rotary or gravure;

[0063] d. embossing resin (2.0 mils);

[0064] e. embossing resin (2.0 mils);

[0065] f. film back ply (e.g. Tedlar Type 5, 2.0 mils);

[0066] g. substrate application adhesive.

[0067] This laminate is formed with an initial 2.0 mil thick embossinglayer. The Tedlar SP layer is printed with the desired print design byrotary or gravure printing processes as known in the art. The printedTedlar SP layer is then laminated to the embossing resin layers, and tothe back ply layer, Tedlar Type 5. The laminate is embossed through theface ply Tedlar SP layer and the web carrier thereon, into the embossingresin layers. The laminate is coated with a substrate applicationadhesive. The web carrier is stripped off of the Tedlar SP layer afterlamination, or after final application of the laminate to a substrate,to thereby serve as a protective mask.

EXAMPLE 5

[0068] A colored dimensionally stable laminate made with colored vinyland a protective polymer film cover.

[0069] a. web carrier, 1 mil;

[0070] b. 0.5 mil polyvinylflouride, non-oriented film solution cast onto web carrier, e.g. Type 8, Tedlar SP;

[0071] c. colored vinyl, e.g. 14-16 mil;

[0072] d. substrate application adhesive.

[0073] The Tedlar SP and vinyl layers are laminated and embossed underpressure and heat, and a substrate application adhesive applied to thevinyl layer. The web carrier is stripped off after lamination or at anytime prior to or after final application of the laminate to a substrateto thereby serve as a protective mask.

EXAMPLE 6

[0074] A dimensionally stable printed and textured laminate made withtwo strippable web carriers, one of polyester and one of paper, and anacrylic resin back ply.

[0075] a. polyester web carrier, 1 mil;

[0076] b. 0.5 mil polyvinylflouride, non-oriented film solution cast onto web carrier, e.g. Type 8, Tedlar SP;

[0077] c. one or more print layers;

[0078] d. embossing resin, 2-4 mils;

[0079] e. acrylic film, 2 mils;

[0080] f. paper web carrier, e.g. 5 mils.

[0081] This laminate is produced with a pre-coating of embossing resin,e.g. 1-2 mils, followed by lamination to a printed Tedlar SP film layerand to another layer of embossing resin, 1-2 mils, and to a back ply ofacrylic resin precoated onto a 2 mil polyester web carrier. The laminatestructure is embossed through the Tedlar SP layer with the web carrierand into the embossing resin. The web carrier is removed from the backof the acrylic layer and the laminate can be coated with a substrateapplication adhesive, heat activated or pressure sensitive. The webcarrier can be stripped from the Tedlar SP layer after lamination, orafter final application to a substrate to thereby serve as a protectivemask during shipping, handling and final application.

EXAMPLE 7

[0082] A dimensionally stable printed and textured laminate made withthe web carrier adhesively bonded to the back of the laminate.

[0083] a. 0.5 mil polyvinylflouride, non-oriented film solution cast onto web carrier, e.g. Type 8, Tedlar SP;

[0084] b. print layer or layers,

[0085] c. embossing resin (2.0 mils);

[0086] d. embossing resin (2.0 mils);

[0087] e. film back ply (e.g. Tedlar Type 3, 2.0 mils);

[0088] f. thermoplastic adhesive that does not distort laminate duringremoval of web carrier

[0089] g. paper web carrier, e.g. 5 mils.

[0090] This laminate is formed with the embossing layers cast andlaminated onto the back film ply Tedlar which has a paper web carrierattached to it with a thermoplastic adhesive. The printed Tedlar SPlayer is then laminated to the embossing resin layers, and to the backply layer, and paper web carrier. The SP web carrier can be removed orstay on for the embossing operation. The laminate is embossed throughthe face ply Tedlar SP layer, into the embossing resin layers. The paperis removed from the laminate after embossing and an optional substrateadhesive is applied.

[0091] These illustrative examples are representative of just a few ofthe many embodiments of the laminates and methods of laminatemanufacture of the invention, each having the common characteristic of aremovable web carrier on at least one of the layers during formation ofthe laminate, which can be removed once the laminate is completed, thebonding force of the carrier providing dimensional stability to thelaminate as a whole and resisting forces between the layers of thelaminate which would otherwise cause distortion of the laminatedimensions and any print patterns on any of the layers.

[0092] As noted, the principles of the invention apply equally to theselection of the web carrier or carriers, and to the selection of layersof the laminate with consideration for balancing distortion relative tothe web carrier, so that the end product laminate remains within designtolerances.

What is claimed as the invention is:
 1. A laminate comprising: a firstpolymer film having a first side and a second side; a web carrierremovably attached to a side of the first polymer film; a print layer onan opposite side of the first polymer film, the print layer having aprint pattern; a second polymer film proximate to the print layer; thefirst and second polymer films being laminated together; the printpattern being substantially free from distortion after lamination as aresult of removable attachment of the web carrier to the first polymerfilm, the web carrier being removable from the first polymer filmwithout distortion of the print pattern.
 2. The laminate of claim 1wherein the first polymer film is cast on to the web carrier.
 3. Thelaminate of claim 1 wherein the web carrier is made of a materialselected from a group of materials of: polyester, paper, rigid polymerfilms, polycarbonate or polyimide, or any other dimensionally stablematerial which can be removably bonded to one or both of the polymerfilm layers.
 4. The laminate of claim 1 wherein the web carrier isdimensionally stable.
 5. The laminate of claim 1 wherein the first andsecond polymer films are made of one or more materials selected from thegroup of: polyvinyl fluoride, polyvinylidene fluoride, polyvinylchloride, acrylic, polyester, polycarbonate, PETG, urethane, ABS orother suitable fluorinated materials or alloys thereof.
 6. The laminateof claim 1 further comprising one or more layers of embossing resinbetween the first and second polymer films.
 7. The laminate of claim 6wherein: the first polymer film has a thickness in a range of about 0.1mil to 10 mils; the embossing resin has an aggregate thickness in arange of about 0.5 mil to 40 mils; and the second polymer film has athickness in a range of 0.5 mil to 40 mils.
 8. The laminate of claim 1wherein the web carrier is bonded to the laminate with a bonding forcesufficient to maintain dimensionally stability of the laminate duringprocessing of the laminate.
 9. The laminate of claim 1 thermally formedas a decorative cover on a structural product.
 10. The laminate of claim6 further comprising at least one layer in addition to the first andsecond polymer films, web carrier and embossing layer.
 11. The laminateof claim 1 further comprising a texture which extends through the webcarrier into the first polymer layer.
 12. The laminate of claim 6further comprising a texture which extends through the web carrier andfirst polymer layer and into the embossing resin.
 13. The laminate ofclaim 6 further comprising a texture in each of the layers of thelaminate.
 14. A laminate product produced by a process comprising thesteps of: providing a first polymer film and a parallel second polymerfilm on one side of the first polymer film; one of the first or secondpolymer films having a web carrier removably attached thereto;laminating the first and second polymers films together, and removingthe web carrier without distortion of the laminated first and secondpolymer films.
 15. The laminate product produced by the process of claim14, further comprising the step of using a first or second polymer filmwhich is cast on to the web carrier.
 16. The laminate product producedby the process of claim 14, further comprising the step of attaching adimensionally stable polyester film as the web carrier to the first orsecond polymer films.
 17. The laminate product produced by the processof claim 14, further comprising the step of forming the first or secondpolymer films from one or more materials selected from the group of:polyvinyl fluoride, polyvinylidene fluoride, polyvinyl chloride,acrylic, polyester, polycarbonate, PETG, urethane, ABS or other suitablefluorinated materials or alloys thereof.
 18. The laminate productproduced by the process of claim 14, further comprising the step ofproviding one or more layers of embossing resin between the first andsecond polymer films.
 19. The laminate product produced by the processof claim 14 wherein the first polymer film has a thickness in a range ofabout 0.1 mil to 10 mils; the embossing resin has an aggregate thicknessin a range of about 0.5 mils. to 40 mils, and the second polymer filmhas a thickness in a range of about 0.5 mil to 40 mils.
 20. The laminateproduct produced by the process of claim 14, further comprising the stepof providing a print layer proximate to the first or second polymerfilms.
 21. The laminate product produced by the process of claim 14,further comprising the step of imparting a texture to the laminate. 22.The laminate product produced by the process of claim 14, furthercomprising the step of imparting a texture to the laminate through theweb carrier by embossing.
 23. The laminate product produced by theprocess of claim 14, further comprising the step of combining the layersof the laminate in a roll-forming process.
 24. The laminate productproduced by the process of claim 14, further comprising the step ofattaching the laminate to a substrate prior to removing the web carrier.25. The laminate product produced by the process of claim 14, furthercomprising the step of providing a web carrier which has a bonding forcewith the first or second polymer film which is greater than forces whichwould distort the first or second polymer films if laminated without theweb carrier.
 26. The laminate product produced by the process of claim14, further comprising the step of selecting the polymer films andembossing resin so that distortional forces exerted by the films whenlaminated are less than a bonding force between the web carrier and oneof the polymer films.
 27. A laminate product comprising: a first polymerfilm; and, a second polymer film positioned in a plane parallel to andon a first side of the first polymer film; a print pattern on orproximate to one of the first or second polymer films; a web carrierremovably attached to one side of the first or second polymer film; thefirst and second polymer films laminated together; the print patternbeing free from distortion after lamination as a result of removableattachment of the web carrier to one of the polymer films duringlamination, and the web carrier being removable from the laminated firstor second polymer films without distortion of the print pattern.
 28. Thelaminate product of claim 27 wherein at least one of the polymer filmsis cast on to the web carrier.
 29. The laminate product of claim 27wherein the web carrier is made of polyester.
 30. The laminate productof claim 27 wherein the first and second polymer films are made of anymaterial selected from the group of: polyvinyl fluoride, polyvinylidenefluoride, polyvinyl chloride, acrylic, polyester, polycarbonate, PETG,urethane or ABS.
 31. The laminate product of claim 27 further comprisingone or more layers of embossing resin between the first and secondpolymer films.
 32. The laminate product of claim 27 in which the firstpolymer film has a thickness in a range of about 0.1 mil to 10 mils; theembossing resin has an aggregate thickness in a range of about 0.5 milto 40 mils, and the second polymer film has a thickness in a range ofabout 0.5 mil to 40 mils.
 33. The laminate product of claim 27 furthercomprising a texture which extends through the web carrier and into thefirst or second polymer films.
 34. The laminate product of claim 33wherein the texture extends through web carrier, first or second polymerfilms, and into the embossing resin.
 35. The laminate product of claim27 with the web carrier removed from the laminated first and secondpolymer films.
 36. The laminate product of claim 27 wherein each of thefirst and second polymer films has a removably attached web carrier. 37.A dimensionally stable laminate product comprising: a first polymerfilm; a web carrier removably attached to one side of the first polymerfilm; a second polymer film on a side of the first polymer film oppositethe web carrier; the first and second polymers films laminated together;the laminated first and second polymer films being dimensionally stablerelative to dimensions of the first and second polymer films prior tolamination as a result of the removable attachment of the web carrier tothe first polymer film, and the laminated first and second polymer filmsbeing dimensionally stable after removal of the web carrier.
 38. Thedimensionally stable laminate product of claim 37 wherein the firstpolymer film is cast on to the web carrier.
 39. The dimensionally stablelaminate product of claim 37 wherein the web carrier is made ofpolyester.
 40. The dimensionally stable laminate product of claim 37wherein the first and second polymer films are made of one or morematerials selected from the group of: polyvinyl fluoride, polyvinylidenefluoride, polyvinyl chloride, acrylic, polyester, polycarbonate, PETG,urethane, ABS or other suitable fluorinated materials or alloys thereof.41. The dimensionally stable laminate product of claim 37 furthercomprising a print proximate to the first or second polymer film,wherein the print remains free from distortion after removal of the webcarrier.
 42. The dimensionally stable laminate product of claim 37further comprising a second web carrier removably attached to the secondpolymer film.
 43. The dimensionally stable laminate product of claim 42wherein the second web carrier is made of a material selected from thegroup of: polyester, paper, rigid polymer films, polycarbonate orpolyimide, or any other dimensionally stable material which can beremovably bonded to one or both of the polymer film layers.
 44. Thedimensionally stable laminate product of claim 37 further comprising oneor more layers of embossing resin between the first and second polymerfilms.
 45. The dimensionally stable laminate product of claim 37 whereinthe first polymer film has a thickness in a range of about 0.1 mil to 10mils, and the second polymer film has a thickness in a range of about0.5 mil to 40 mils.
 46. The dimensionally stable laminate product ofclaim 43 wherein the embossing resin layer or layers has a thickness inthe range of 0.5 mil to 40 mils.
 47. The dimensionally stable laminateproduct of claim 37 further comprising a texture which extends throughthe web carrier and into the first polymer film.
 48. The dimensionallystable laminate product of claim 38 further comprising a texture whichextends through the web carrier and into the first polymer film and theembossing resin.
 49. The dimensionally stable laminate product of claim37 further comprising a substrate attachment adhesive on the secondpolymer film.
 50. The dimensionally stable laminate product of claim 37attached to a substrate.
 51. The dimensionally stable laminate productof claim 37 further comprising a print layer between the first andsecond polymer films.
 52. A method of making a dimensionally stabledecorative laminate which has a print pattern with dimensions whichremain substantially the same prior to and after lamination of layers ofthe laminate, the method comprising the steps of: providing a firstpolymer layer with an attached web carrier; providing a second polymerlayer; providing a print pattern between the first polymer layer and thesecond polymer layer; laminating the first and second polymer layerstogether, and removing the web carrier from the first polymer layer. 53.The method of claim 52 wherein the print pattern is applied directly tothe first polymer layer opposite the web carrier.
 54. The method ofclaim 52 wherein the print pattern is on a separate print layerpositioned between the first and second polymer layers. 55 The method ofclaim 52 wherein the first and second polymer layers are laminatedtogether by rollers.
 56. The method of claim 52 further comprising thestep of providing embossing resin between the first and second polymerlayers.
 57. The method of claim 52 further comprising the step ofcasting the first polymer layer on to the web carrier prior tolamination of the first and second polymer layers.
 58. The method ofclaim 52 further comprising the step of providing a second web carrierremovably attached to the second polymer layer.
 59. The method of claim52 further comprising the step of imparting a texture to the firstpolymer layer through the web carrier.
 60. The method of claim 52further comprising the step of applying a substrate attachment adhesiveto the second polymer layer.
 61. The method of claim 52 furthercomprising the step of attaching the laminate to a substrate prior toremoving the web carrier from the first polymer layer.
 62. The method ofclaim 52 further comprising the step of imparting a texture to thelaminate through the second polymer layer.